Redox reaction facilitated carbon dioxide capture from flue gas and conversion to carbon monoxide

ABSTRACT

Exemplary reactor systems may include multiple reactors in fluid communication. Oxygen carrier particles comprising a support material and metal oxide can be provided to a first reactor along with flue gas comprising carbon dioxide (CO2). An output of the first reactor is free or substantially free of carbon dioxide (CO2). The oxygen carrier particles can then be provided to one or more reactors in the system along with a hydrocarbon stream and, in some instances, an oxidizing stream. Outlets from these one or more reactors may include hydrogen gas (H2), carbon monoxide (CO), and/or other species, depending upon the content of the hydrocarbon streams and the oxidizing streams.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is related to and claims the priority benefit of U.S. Provisional Patent Application No. 62/895,109, filed Sep. 3, 2019, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to chemical looping systems and methods. More particularly, exemplary chemical looping systems convert carbon dioxide in flue gas to carbon monoxide.

INTRODUCTION

Syngas is a mixture of hydrogen and carbon monoxide that is an important intermediate compound for fuel and chemical production. Several syngas production technologies exist which are both process and energy intensive. Steam reforming and dry reforming are endothermic reactions for syngas production with CH₄ as the hydrocarbon feedstock which utilize H₂O and CO₂, respectively. The endothermic heat is provided by burning CH₄, which results in carbon emissions. Auto-thermal reforming is exothermic in nature but requires an energy intensive air separation unit. The energy consumption in the form of electricity also leads to carbon emissions. Syngas can also be generated using solid fuels such as coal, biomass etc. and liquid fuels such as residual oil etc. through gasification reactions. These processes also suffer from high energy requirements, ultimately driving the carbon footprint of such systems.

Similar to syngas, hydrogen is also an important chemical intermediate and is used for the production of value-added chemicals such as ammonia. Typically, hydrogen is produced by steam methane reforming along with a water gas shift reactor and an acid gas removal unit. Both the production of syngas and hydrogen requires several unit operations which lowers the overall efficiency and thus are required to rely on economies of scale for them to be economically viable.

SUMMARY

In one aspect, a method of operating a reactor system is disclosed. An exemplary method may include providing oxygen carrier particles to a first reactor, where the oxygen carrier particles comprise a support material and metal oxide; providing flue gas comprising carbon dioxide (CO₂) to the first reactor; operating the first reactor at a temperature of 300° C. to 700° C.; collecting a first reactor gas output comprising less than 1 ppb CO₂; providing the oxygen carrier particles to a second reactor; providing a hydrocarbon stream to the second reactor; operating the second reactor at a temperature of 500° C. to 1100° C.; collecting a second reactor gas output comprising hydrogen gas (H₂) and carbon monoxide (CO); providing the oxygen carrier particles to a third reactor; providing an oxidizing stream to the third reactor; and collecting a third reactor gas output comprising carbon monoxide (CO).

In another aspect, a reactor system is disclosed. An exemplary reactor system may include a first reactor, a second reactor in fluid communication with the first reactor, and a third reactor in fluid communication with the second reactor. The first reactor may comprise oxygen carrier particles comprising a support material and metal oxide, a flue gas inlet in fluid communication with a flue gas source, the flue gas source providing flue gas comprising carbon dioxide (CO₂) to the first reactor; and a first reactor gas outlet configured to provide outlet gas comprising less than 1 ppb CO₂. The second reactor may comprise a hydrocarbon stream input in fluid communication with a hydrocarbon source, the hydrocarbon source configured to provide coal, biomass, natural gas, shale gas, biogas, or petroleum coke to the second reactor; and a second reactor gas outlet configured to provide a second reactor gas output comprising hydrogen gas (H₂) and carbon monoxide (CO). The third reactor may comprise an oxidizing stream inlet in fluid communication with an oxidizing gas source comprising one or more of: steam (H₂O), carbon dioxide (CO₂); and a third reactor outlet gas outlet configured to provide a third reactor gas output comprising carbon monoxide (CO).

In another aspect, a method of operating a reactor system is disclosed. An exemplary method may include providing oxygen carrier particles to a first reactor, the oxygen carrier particles comprising a support material and metal oxide; providing flue gas comprising carbon dioxide (CO₂) to the first reactor; operating the first reactor at a temperature of 300° C. to 700° C.; collecting a first reactor gas output comprising less than 1 ppb CO₂; providing the oxygen carrier particles to a second reactor; providing a hydrocarbon stream to the second reactor; providing an oxidizing stream to the second reactor such that the oxidizing stream is counter-current to the oxygen carrier particles; operating the second reactor at a temperature of 720° C. to 1100° C.; and collecting a second reactor gas output comprising hydrogen gas (H₂) and carbon monoxide (CO).

There is no specific requirement that a material, technique or method relating to chemical looping carbon dioxide capture include all of the details characterized herein, in order to obtain some benefit according to the present disclosure. Thus, the specific examples characterized herein are meant to be exemplary applications of the techniques described, and alternatives are possible.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an example embodiment of a reactor system.

FIG. 2 is a schematic diagram of another example embodiment of a reactor system.

FIG. 3 is a schematic diagram of another example embodiment of a reactor system.

FIG. 4 is a schematic diagram of another example embodiment of a reactor system.

FIG. 5 is a schematic diagram of another example embodiment of a reactor system.

FIG. 6A shows experimental thermogravimetric analysis of solid conversion trends across 10 redox cycles for Ca₂Fe₂O₅ particles reacted with methane (CH₄). FIG. 6B shows experimental thermogravimetric analysis of regeneration of reduced Ca₂Fe₂O₅ particles using carbon dioxide (CO₂).

FIG. 7 shows experimental carbon dioxide (CO₂) uptake and release in Ca₂Fe₂O₅ particles as a function of temperature.

FIG. 8 shows experimental values for steady state concentration profiles of products from fixed bed experiments run with the unsupported and supported Ca₂Fe₂O₅ particles at 1000° C.

FIG. 9 shows experimental values for regeneration of reduced unsupported and supported Ca₂Fe₂O₅ particles in carbon dioxide (CO₂).

FIG. 10 is a phase diagram for Ca₂Fe₂O₅ particles with log(ppCO₂) versus temperature.

FIG. 11 is a phase diagram for CaO particles with log(ppCO₂) versus temperature.

DETAILED DESCRIPTION

The instant disclosure provides various designs and operating strategies for harnessing fossil fuel energy through chemical looping. Syngas and hydrogen are important intermediate compounds for the fuel and chemical production industries. Current technologies for the conversion of various hydrocarbon sources to syngas or hydrogen require several energy intensive units. The energy is utilized in the form of electricity or heat, both being derived from burning fossil fuels. This leads to an increase in the carbon emissions per mole of syngas/hydrogen produced.

Exemplary systems and methods disclosed herein can generate products such as syngas, hydrogen, or electricity, while capturing CO₂ from flue gas streams and integrating the captured CO₂ into the system. Exemplary operating strategies may involve capturing CO₂ using metal oxide oxygen carriers leading to the formation of metal carbonate-oxide mixtures, which may be further used to partially oxidize hydrocarbon feedstock for syngas production. Reduced oxygen carriers may be regenerated completely or partially with oxidants such as steam, CO_(2,) or air to complete a loop.

Exemplary systems and methods disclosed herein may mitigate carbon emissions through process intensification and flexibility towards different hydrocarbon feedstock and heat sources. CO₂ may be captured from flue gas and converted simultaneously to CO in the same process, because this conversion may be facilitated by the redox reaction for syngas or hydrogen production.

In exemplary chemical looping systems, carbonate decomposition may be facilitated by syngas production, which can enable a reduction of the operating temperature of the calcination reaction and improve the thermal efficiency of CO₂ capture and utilization. Various configurations described herein may efficiently utilize the thermodynamic potential of the oxygen carrier material.

I. Exemplary Oxygen Carrier Particles

Broadly, exemplary systems and methods utilize oxygen carrier particles. Exemplary oxygen carrier particles are capable of undergoing reduction/oxidation reactions that change the oxidation state of one or more species, or reactions that change the solid phase of one or more species. Exemplary oxygen carrier particles may be metal oxides, metal carbonates, metal alloys, or combinations thereof. Certain design considerations for exemplary oxygen carrier particles can include reactivity, recyclability and mechanical strength, along with oxygen/CO₂ carrying capacity.

Exemplary metal oxide composites may have at least one of the active metals as iron. Exemplary mixed metal composites can be one single phase or can be a mixture of several active phases. The composite can comprise more than one active metal capable of a change in oxidation state under reducing or oxidizing environments, or that undergoes phase change under a partial pressure of CO₂.

Other transition metal oxides such as nickel oxide, copper oxide, cobalt oxide, and manganese oxide can be an active metal oxide in conjunction with iron. Nickel oxide, copper oxide, and other transition metal oxides appear to be particularly suited because of their high oxygen carrying capacity and good reactivity among all the transition metal oxide candidates. Group I and II metal oxides such as MgO, CaO, Na₂O etc. can also be considered as active metals/metal oxides because of their high affinity towards CO₂ through carbonate formation.

The recyclability of exemplary oxygen carriers can be promoted by adding supportive oxides, also termed support materials, which may also affect the lattice oxygen ion diffusivity. The support material can be any support material known and used in the art. Non-limiting examples of support materials include, but are not limited to, silica, magnesia, alumina, ceria, titania, zirconia, or a combination comprising two or more of the aforementioned supports such as MgAl₂O₄. The amount of support material can be 20% to 80% by weight (wt %) of the oxygen carrier. In various implementations, exemplary oxygen carriers may comprise 20 wt %, 30 wt % 40 wt %, 50 wt %, 60 wt %, 70 wt %, 80 wt % or any value therebetween.

Inert carbonate materials such as K2CO₃ can also be included as a part of the overall composite solid which can later combine with the carbonate phase to form a mixed metal carbonate.

In some implementations, metal oxide reactivity can be enhanced by low concentration dopant modification. One or more dopants may comprise 0 wt % to about 5 wt % of the oxygen carrier particles. In various instances, oxygen carrier particles may comprise 0 wt % to 5 wt %; 1 wt % to 5 wt %; 2 wt % to 5 wt %; 3 wt % to 5 wt %; 1 wt % to 4 wt %; 1 wt % to 3 wt %; 1 wt % to 2 wt %; 2 wt % to 3 wt %; 3 wt % to 4 wt %; or 4 wt % to 5 wt % dopant.

Exemplary dopants can have one or more of the following impacts in reactivity enhancement of cyclic chemical looping redox reactions. Exemplary catalytic dopants can provide extra reaction sites during CO₂ capture and hydrocarbon conversion in addition to the host transition metal oxides such as iron oxide. The nature of aliovalent dopants, such as Cu²⁺, Co²⁺, Ni²⁺ vs Fe³⁺, may result in an increase of oxygen vacancies, which may promote oxygen ion transport in methane partial oxidation and improves the syngas quality. Exemplary catalytic dopants can lower reaction energy barrier of CO₂ capture and C—H activation with the host transition metal oxide materials. Example catalytic transition metal dopants include, but are not limited to, Ni, Co, Cu, Sc, Ti, V, Cr, Mn, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Lu, Hf, Ta, W, Re, Os, Ir, Pt, and Au.

II. Exemplary Reactor System Arrangements

Broadly, exemplary reactor systems disclosed herein convert hydrocarbon feed and an external source of energy into syngas, hydrogen, or both. Additionally, exemplary reactor systems may capture carbon dioxide (CO₂), which may be facilitated by redox reactions in system reactors.

FIG. 1 is a schematic diagram of example reactor system 100 that includes a first reactor (R1), a second reactor (R2), a third reactor (R3), and an optional fourth reactor (R4). Generally, reactor system 100 is a multi-reactor chemical looping system that can simultaneously generate syngas, hydrogen and treat flue gas for CO₂ removal. Each reactor in exemplary reactor system 100 can be operated independently at pressures ranging from 1 atm to 50 atm, depending on desired feed/product parameters. The individual reactors can be modified/removed as long as the oxygen carrier particles return to the original solid phase to complete the loop.

First reactor (R1) can include a plurality of oxygen carrier particles that comprise a support material and metal oxide. First reactor (R1) can also include a flue gas inlet in fluid communication with a flue gas source. In some instances, a flue gas source may provide flue gas comprising carbon dioxide (CO₂) to the first reactor. First reactor (R1) can include a first reactor gas outlet configured to provide outlet gas. First reactor (R1) is also provided with heat from a heat source.

Example composite oxygen carrier particles depicted by M_(a)M_(b)O function as an oxygen carrier and a CO₂ carrier. In FIG. 1, Ma and Mb represent active metal components that can either undergo redox reactions with the gas phase or can undergo a phase transformation into a different solid phase. The composite metal oxide oxygen carrier is not limited two active metals and additional details on the metal oxide characteristics are discussed in greater detail above.

Example composite oxygen carriers react with CO₂ from flue gas in reactor R1 under moderate temperature (such as 300° C.-700° C.) and can be converted to (M_(a)X)-(M_(b)O), where M_(a)X is metal carbonate phase and MbO is metal oxide phase of the oxygen carrier. Conversion of M_(a)M_(b)O to (M_(a)X)-(MbO) ensures CO₂ capture in the form of metal carbonate, thus making flue gas CO₂ free. The gas-solid hydrodynamics in reactor R1 can be in the form of a moving bed, entrained bed or fluidized bed configurations.

Second reactor (R2) is in fluid communication with first reactor (R1) and third reactor (R3). Second reactor (R2) can include a hydrocarbon stream input in fluid communication with a hydrocarbon source and a second reactor gas outlet configured to provide a second reactor gas output. Second reactor (R2) is also provided with heat from a heat source. (M_(a)X)-(M_(b)O) metal carbonate-oxide composite may be provided from first reactor (R1) to second reactor (R2) along with a hydrocarbon source such as coal, biomass, petroleum coke, residual oil, shale gas, natural gas, etc. Second reactor (R2) may be operated at high temperatures (800° C. -1100° C.) under co-current/countercurrent gas-solid flow in either a moving bed/entrained bed configuration or a combination of both.

The configuration of second reactor (R2) can be tuned to maximize the thermodynamic potential of the gas-solid reactions to produce syngas, and additional examples are discussed below with reference to FIG. 2-FIG. 5. At the high temperatures in second reactor (R2), M_(a)X may decompose to release CO₂ and form M_(a)M_(b)O. The CO₂ released in this step may gasify/reform the hydrocarbon feed and produce CO. M_(a)M_(b)O may also react with the hydrocarbon feed and produce a H2/CO mixture, commonly known as syngas. To adjust an H₂:CO ratio, steam, methane, and/or carbon dioxide (CO₂) can be co-injected along with the feed.

Third reactor (R3) is in fluid communication with second reactor (R2) and either fourth reactor (R4) or, in implementations without a fourth reactor, the first reactor (R1). Third reactor (R3) can include an oxidizing stream inlet in fluid communication with an oxidizing gas source and a third reactor gas outlet configured to provide a third reactor gas output. Second reactor (R2) is also provided with heat from a heat source.

Reduced metal oxide oxygen carrier M_(a)-M_(b)O_(1-x) may be provided from the second reactor (R2) to the third reactor (R3). In the third reactor (R3), reduced metal oxide oxygen carrier particles may react with H₂O/CO₂ to produce H₂/CO and become oxidized to M_(a)M_(b)O_(1-y) (where x>y). The third reactor (R3) may be operated at a moderate reaction temperature (400° C.-900° C.).

Optional fourth reactor (R4) is in fluid communication with the third reactor (R3) and the first reactor (R1). The fourth reactor (R4) can include an air stream inlet and a depleted air outlet. Solids may be mechanically or pneumatically conveyed from the fourth reactor (R4) to the first reactor (R1).

Partially oxidized oxygen carrier particles may be provided from third reactor (R3) to the fourth reactor (R4). In the fourth reactor (R4), the oxygen carrier particles may be completely oxidized using air and then provided to the first reactor (R1) to complete the loop. Operating temperatures of the fourth reactor (R4) may be 500° C-1100° C. In some instances, the fourth reactor (R4) can be coupled with an in-bed heat exchanger to extract any additional heat generated. The solids from R4 to R1 can be mechanically or pneumatically conveyed.

In some implementations, a solids stream coming out of the second reactor (R2) can be split into two streams: where one stream goes to the third reactor (R3) and the other stream bypasses the third reactor (R3) to go directly to the fourth reactor (R4). The split ratio can be adjusted based on process requirements of the overall system.

As shown in FIG. 1, first reactor (R1), second reactor (R2), and third reactor (R3) can be integrated independently with an external source of heat. Exemplary heat sources can be provided from carbon containing sources by burning hydrocarbon fuels or through low-carbon or no-carbon sources. These low or no carbon sources may include, but are not limited to, solar energy, geothermal energy, nuclear energy, hydrogen combustion, and microwave heating. Reactions in the fourth reactor (R4) may be highly exothermic and, accordingly, the fourth reactor (R4) typically does not require an external heating source.

The heat provided to the reactors can be through direct systems, indirect systems, or combinations of the two systems, and can heat the metal oxide/metal carbonate solids or the gas phase. Direct systems can include traditional systems such as in-bed combustion of fuels. Advanced systems can include concentrated solar power, direct microwave radiation, and chemical looping combustion systems.

Exemplary indirect heat systems may have a heat transfer medium between the source of the heat and the reactors in the chemical looping configuration. This heat transfer medium can be in a liquid phase, gas phase, or both phases. Traditional methods of employing a furnace box that surrounds the reactors can be used to provide radiative and convective heat to the reactors. Advanced methods of having in-bed heat exchangers such as moving bed or fluidized bed heat exchangers can be used to provide the heat to the reactors. In all configurations, a goal is to mitigate the overall carbon emissions using in-process carbon capture techniques in the first reactor (R1), and/or through using advanced heat generation systems such as chemical looping combustion or the use of renewable sources of heat.

For illustrative purposes only, and without limitation, the following are example reactions in each of the four reactors shown in FIG. 1. The exemplary reactions have oxygen carrier particles comprising Ca₂Fe₂O₅+Fe₂O₃.

-   First Reactor (R1): Ca₂Fe₂O₅+2CO₂→2CaCO₃+Fe₂O₃ -   Second Reactor (R2): CaCO₃→CaO+CO₂2CaO+Fe₂O₃→Ca₂Fe₂O₅C+CO₂→2CO     Ca₂Fe₂O₅+H/C→CaO+Fe+H₂+CO -   Third Reactor (R3): 2CaO+2Fe+3H₂O→Ca₂Fe₂O₅+3H₂3Fe+4H₂O→Fe₃O₄+4H₂ -   Fourth Reactor (R4): Ca₂Fe₂O₅+2Fe₃O₄+0.5 O₂(air)→Ca₂Fe₂O₅+3Fe₂O₃

FIG. 2 is a schematic diagram of example reactor system 200. Reactor system 200 includes components shown in reactor system 100 as well as fifth reactor (R1′) and sixth reactor (R2′)

In reactor system 200, heat needed to carry out reactions in second reactor (R2) is provided by another chemical looping unit 202, which comprises fifth reactor (R1′) and sixth reactor (R2′). Hydrocarbon feed such as coal, biomass, petcoke, shale gas, natural gas, etc. may be fed into fifth reactor (R1′), where the hydrocarbon feed may be reacted with fully oxidized metal oxide oxygen carriers to produce either full or partial combustion products.

Reduced oxygen carrier particles may be sent to the sixth reactor (R2′) where they may be regenerated using air. The regeneration reaction is exothermic and generates heat, which is used to operate chemical looping system 202 under auto-thermal conditions. Excess heat produced in sixth reactor (R2′) is used to raise the temperature inside the second reactor (R2). The chemical looping heat source 202 in reactor system 200 avoids the use of an energy intensive air separation unit and separates the CO₂/CO for either sequestration or use as a feedstock. This configuration not only captures CO₂ from flue gas, but also captures CO₂ that may be emitted from the heat generation process.

FIG. 3 is a schematic diagram of example reactor system 300 that includes first reactor (R1), second reactor (R2), third reactor (R3), and riser (Ri). The first reactor (R1) is in fluid communication with the second reactor (R2), the second reactor (R2) is in fluid communication with the first reactor (R1) and the third reactor (R3), the third reactor (R3) is in fluid communication with the second reactor (R2) and the riser (Ri), and the riser (Ri) is in fluid communication with the third reactor (R3) and the first reactor (R1).

First reactor (R1) and second reactor (R2) are configured as described above with reference to reactor system 100. Reactor system 300 differs from reactor system 100 in that the fourth reactor (R4) is removed in reactor system 300.

Reactor system 300 is configured such that partially oxidized composite metal oxide oxygen carrier particle M_(a)M_(b)O_(1-x) that enters third reactor (R3) is completely oxidized to its original oxidation state i.e. M_(a)M_(b)O. Solids can be mechanically or pneumatically conveyed from third reactor (R3) to first reactor (R1).

For illustration purposes only, an example is provided where dicalcium ferrite (Ca₂Fe₂O₅) is the composite metal oxide oxygen carrier in reactor system 300. In that example, the following reactions may occur.

-   First Reactor (R1): Ca₂Fe₂O₅+2CO₂→2CaCO₃+Fe₂O₃ -   Second Reactor (R2): CaCO₃→CaO+CO₂2CaO+Fe₂O₃→Ca₂Fe₂O₅ C+CO₂→2CO     Ca₂Fe₂O₅+H/C→CaO+Fe+H₂+CO -   Third Reactor (R3): 2CaO+2Fe+3H₂O→Ca₂Fe₂O₅+3H₂

FIG. 4 is a schematic diagram of example reactor system 400 that includes a modified configuration for the third reactor (R3). Otherwise, reactor system 400 can include the same or similar components shown in reactor system 100. In reactor system 400, flue gas containing NO_(x) and CO₂ may be used to oxidize reduced composite metal oxide particles instead of steam in third reactor (R3). The first reactor (R1), second reactor (R2), and fourth reactor (R4) may operate as described above with reference to reactor system 100.

In reactor system 400, third reactor (R3) can produce N₂ and CO from the flue gas stream. In some instances, steam can be injected along with flue gas to obtain N₂-containing syngas to increase the overall syngas yield of the process.

For illustration purposes only, and without limitation, an example is provided where dicalcium ferrite is the composite metal oxide oxygen carrier reactor system 400. In that example, the following reactions may occur the second reactor (R2) and third reactor (R3).

-   Second Reactor (R2): CH₄+Ca₂Fe₂O₅→2CaO+2Fe+3CO+6H₂ -   Third Reactor (R3): 2CaO+2Fe+3CO₂→Ca₂Fe₂O₅+3CO     8CaO+8Fe+6NO₂→4Ca₂Fe₂O₅+3N₂

FIG. 5 is a schematic diagram of example reactor system 500 that includes first reactor (R1) and second reactor (R2). The first reactor (R1) may operate as described above with reference to reactor system 100.

In reactor system 500, the second reactor (R2) may have a cross-current moving bed configuration. The first reactor (R1) functions as the CO₂ capture reactor, similar to reactor system 100. In the second reactor (R2), carbon source(s) such as coal, biomass, petcoke, and methane (CH₄) may devolatilize upon entering the heated reactor and react with the metal oxide-metal carbonate. In the first half of the second reactor (R2), the volatiles may move downwards with oxygen carrier particles in a concurrent fashion, where oxygen carrier particles partially oxidize the volatiles to form H₂/CO. Char/tar formed upon decomposition of solid fuels may react with steam/CO₂, which may be fed into the second reactor (R2) at, or near, the bottom in a counter-current manner with respect to flow of the oxygen carrier particles.

Oxidants such as steam and CO₂ can gasify the carbon present in char/tar and generate more syngas, thus increasing the overall yield of syngas production. A top portion of the moving bed second reactor (R2) may behave as a co-current moving bed, whereas the bottom portion may operate in a counter-current fashion with the outlet syngas coming out of the middle. Examplary oxidants may also react with reduced oxygen carrier particles and regenerate the particles completely. Regenerated oxygen carrier particles may be then circulated back to the first reactor (R1) to complete the loop.

For illustration purposes only, an example is provided where dicalcium ferrite (Ca₂Fe₂O₅) is the composite metal oxide oxygen carrier reactor system 500. In that example, the following reactions may occur:

-   First Reactor (R1): Ca₂Fe₂O₅+2CO₂→2CaCO₃+Fe₂O₃ -   Second Reactor (R2): CaCO₃→CaO+CO₂2CaO+Fe₂O₃→Ca₂Fe₂O₅C+CO₂→2CO     Ca₂Fe₂O₅+H/C→CaO+Fe+H₂+CO 2CaO+2Fe+3H₂O→Ca₂Fe₂O₅+3H₂

III. Exemplary Methods of Operation

Exemplary reactor systems described above may be operated in various ways.

An example method may include providing oxygen carrier particles to a first reactor. The oxygen carrier particles typically comprise a support material and metal oxide. Various aspects of exemplary oxygen carrier particles are described above. In some instances, the metal oxide may be an oxide of calcium (Ca), iron (Fe), nickel (Ni), copper (Cu), manganese (Mn), cobalt (Co), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba). In some instances, the support material may comprise silica (SiO₂), magnesia (MgO), alumina (Al₂O₃), ceria (CeO₂), Titania (TiO₂), zirconia (ZrO₂), or combinations thereof. In some instances, the oxygen carrier particles may comprise 20 weight percent (wt %) to 80 wt % support material.

The example method also includes providing flue gas to the first reactor, where the flue gas comprises carbon dioxide (CO₂). In various implementations, the first reactor may be arranged as a co-current moving bed, a counter-current moving bed, a fixed bed, or a fluidized bed.

Typically, a metal oxide-metal carbonate solid-phase mixture can be formed when the oxygen carrier particles contact the flue gas. In some instances, the metal oxide-metal carbonate solid-phase mixture includes one or more carbonates of calcium (Ca), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba).

The first reactor may be operated at a temperature of about 300° C. to about 700° C. In various implementations, the first reactor may be operated at a temperature of 300° C. to 700° C.; 300° C. to 500° C.; 500° C. to 700° C.; 400° C. to 700° C.; 300° C. to 600° C.; 400° C. to 660° C.; 300° C. to 400° C.; 400° C. to 500° C.; 500° C. to 600° C.; or 600° C. to 700° C.

The first reactor may be operated at a pressure of about 1 atm to about 50 atm. In various implementations, the first reactor may be operated at a pressure of 1 atm to 50 atm; 1 atm to 25 atm; 25 atm to 50 atm; 1 atm to 10 atm; 10 atm to 20 atm; 20 atm to 30 atm; 30 atm to 40 atm; 40 atm to 50 atm; 1 atm to 5 atm; 1 atm to 3 atm; 3 atm to 6 atm; or 6 atm to 10 atm.

The example method may also include collecting a first reactor gas output. The first reactor gas output is free of, or nearly free of, carbon dioxide (CO₂). A carbon dioxide concentration in the first reactor gas output may vary depending on parameters such as oxygen carrier particle flow rate and reactor temperature. In various instances, the first reactor gas output may comprise less than 1 ppm; less than 100 ppb; less than 10 ppb; or less than 1 ppb carbon dioxide (CO₂).

Next, the oxygen carrier particles can be provided from the first reactor to the second reactor. A hydrocarbon stream may also be provided to the second reactor. In various implementations, the second reactor may be arranged as a co-current moving bed, a counter-current moving bed, a fixed bed, or a fluidized bed.

The hydrocarbon stream may include coal, biomass, natural gas, shale gas, biogas, petroleum coke, or combinations thereof. In some implementations, steam and/or carbon dioxide (CO₂) can be co-injected with the hydrocarbon stream. In some instances, co-injecting steam and/or carbon dioxide (CO₂) may enhance syngas quality and/or enable manipulation of the H₂: CO ratio in the second reactor.

The second reactor may be operated at a temperature of about 500° C. to 1100° C. In various implementations, the second reactor may be operated at a temperature of 500° C. to 1100° C.; 500° C. to 800° C.; 600° C. to 1000° C.; 700° C. to 1100° C.; 720° to 910° C.; 910° C. to 1100° C.; 720° C. to 1000° C.; 800° C. to 1100° C.; 500° C. to 600° C.; 600° C. to 700° C.; 700° C. to 800° C.; 800° C. to 900° C.; 900° C. to 1000° C.; or 1000° C. to 1100° C.

The second reactor may be operated at a pressure of about 1 atm to about 50 atm. In various implementations, the second reactor may be operated at a pressure of 1 atm to 50 atm; 1 atm to 25 atm; 25 atm to 50 atm; 1 atm to 10 atm; 10 atm to 20 atm; 20 atm to 30 atm; 30 atm to 40 atm; 40 atm to 50 atm; 1 atm to 5 atm; 1 atm to 3 atm; 3 atm to 6 atm; or 6 atm to 10 atm.

The example method may also include collecting a second reactor gas output. In some instances, the second reactor gas output comprises hydrogen gas (H₂) and carbon monoxide (CO).

The example method may also include providing the oxygen carrier particles to a third reactor from the second reactor. An oxidizing stream may also be provided to the third reactor and a third reactor gas output may be collected. Then, the oxygen carrier particles may be provided from the third reactor to the first reactor or to a fourth reactor. In some implementations, the oxygen carrier particles are provided from the third reactor to a riser, and then the oxygen carrier particles are provided from the riser to the first reactor.

In some implementations, the oxidizing stream may comprise steam (H₂O) and carbon dioxide (CO₂) and the third reactor gas output may comprise carbon monoxide (CO), hydrogen gas (H₂). In some implementations, the oxidizing stream may comprise steam (H₂O), carbon dioxide (CO₂), and air, and the third reactor gas output may comprise carbon monoxide (CO), hydrogen gas (H₂) and depleted air (lean O₂). In some implementations, the oxidizing stream may comprise an oxide of nitrogen (NO_(x) and carbon dioxide (CO₂), and the third reactor gas output may comprise carbon monoxide (CO) and nitrogen (N₂).

The example method may also include, in some implementations, providing the oxygen carrier particles to a fourth reactor and providing an air stream to the fourth reactor. A fourth reactor gas output may be collected that comprises depleted air. Then the oxygen carrier particles may be provided to the first reactor.

In some instances, the example method may include operating a second reactor system. In those implementations, the example method may include providing second oxygen carrier particles and a second hydrocarbon stream to a fifth reactor. The second oxygen carrier particles may have some of all of the characteristics described above with reference to oxygen carrier particles.

A fifth reactor gas output may be collected that comprises a mixture of hydrogen gas (H₂), steam (H₂O), carbon monoxide (CO), and/or carbon dioxide (CO₂). In some instances, the fifth reactor gas output may comprise a mixture of carbon dioxide (CO₂) and steam (H₂O).

The second oxygen carrier particles may be provided from the fifth reactor to the sixth reactor. Air may also be provided to the sixth reactor, and a sixth reactor gas output may be collected that comprises depleted air. Then heat generated in the sixth reactor may be provided to the second reactor.

IV. Experimental Examples

Experimental examples were conducted to validate the use of Ca₂Fe₂O₅ or similar types of metal oxide-based oxygen carriers in chemical looping systems. Performance of this oxygen carrier was evaluated through use of thermogravimetric analysis (TGA) and fixed bed experiments. Two samples were used for analysis: unsupported Ca₂Fe₂O₅ and 40% MgO supported (by wt.) Ca₂Fe₂O₅.

A. Experimental Thermogravimetric Analysis

FIG. 6A and FIG. 6B show solid conversion obtained during 10 cyclic reduction and oxidation steps at 1000° C. and 1 atm. The reduction of the metal oxide was carried out in CH₄ (20% by vol. with total flowrate of 200 ml/min) and the oxidation of the metal oxide was carried out in CO₂. A Setaram SETSYS TGA was used to analyze the weight change data. About 30-35 mg sample was loaded into an alumina crucible suspended from the mechanical balance of TGA. Helium (He) was used as a protective gas to prevent CH4 seepage into the balance. Low sample loading and high gas flows ensured no mass transfer limitation during the experiment. Sample regeneration was carried out by sending 50% CO₂ by volume with a total flow of 200 ml/min, balance with N₂. Here, the solid conversion is defined as the amount of active lattice oxygen donated. Accordingly, the solid phase Ca₂Fe₂O₅ will have a solid conversion of 0% and CaO—Fe will have a solid conversion of 100%.

Solid conversion during reduction initially increased and then dropped for unsupported Ca₂Fe₂O₅ sample. On the other hand, solid conversion increased and maintained its activity across multiple redox cycles for 40% MgO supported Ca₂Fe₂O₅ sample. For both the samples, >95% solid conversion is obtained. Similar performance is expected if CO₂ is replaced using steam due to similar thermodynamic behavior of steam and CO₂ in the presence of Ca₂Fe₂O₅. The support MgO provides sintering resistance towards the redox reactions of Ca₂Fe₂O₅, thus improving its recyclability.

Another set of experiments was carried out in the TGA to assess the CO₂ capture performance of Ca₂Fe₂O₅. Freshly prepared Ca₂Fe₂O₅ sample was heated up to 550° C. and subjected to 40% CO₂ (total flow 200 ml/min, balanced with N2). As seen from FIG. 7, the weight of the sample showed an increase due to the formation of CaCO₃₊Fe₂O₃ arising from the decomposition of Ca₂Fe₂O₅ in presence of CO₂ and its subsequent capture. Once CaCO₃+Fe₂O₃ was formed, the temperature was raised to 650° C. where the sample decomposed and a weight drop was observed in the TGA, which was due to the release of CO₂ and formation of Ca₂Fe₂O₅.

B. Fixed Bed Experiments as a Simulated Moving Bed

Experiments were carried out in a simulated co-current moving bed reactor scheme to determine any effects of MgO addition to Ca₂Fe₂O₅ on parameters like methane conversion, syngas selectivity and H2:CO ratio. An operating temperature of 1000° C. was maintained during the experiment. The ceramic reactor was loaded with fully oxidized sample at the top and partially reduced sample at the bottom in a 1:3 ratio (oxidized to partially reduced) to simulate a co-current moving bed. CH4 (20% with total flowrate of 25 ml/min) was provided into the reactor from the top and gases exiting the reactor from bottom were analyzed using a mass spectrometer. FIG. 8 and Table 1 depict the concentration of the product gas and performance of these metal oxides.

TABLE 1 Performance of the unsupported and supported Ca₂Fe₂O₅ fixed bed runs at 1000° C. Oxygen CH4 Syngas Carrier conversion selectivity H2:CO Particle (%) (%) ratio Ca2Fe2O5 99.52 95.52 2.08 Ca2Fe2O5@ 99.88 98.08 2.03 40% MgO

Methane conversion of >99% was obtained for both the samples with an H₂:CO ratio of ˜2:1, which makes this syngas capable of being used for production of synthetic fuels and higher hydrocarbons through Fisher-Tropsch synthesis. Higher selectivity was obtained when MgO was used as a support because of decrease in adsorption energy of CO as studied using Density Functional Theory (DFT). In the absence of MgO, CO does not desorb readily and as a result gets further oxidized to produce CO₂.

FIG. 9 shows the regeneration of reduced Ca₂Fe₂O₅ using CO₂. The regeneration of reduced samples was carried out by sending 25 ml/min of total gas flow with 40% CO₂ at 1000° C. and 1 atm. Both the oxygen carriers showed complete regeneration in CO₂, and the CO yields obtained were close to the thermodynamic limit.

C. Thermodynamic Estimation of the Flue Gas Capture Reactor

FIG. 10 shows a phase diagram for Ca₂Fe₂O₅with log(ppCO₂) vs temperature. FIG. 11 shows a phase diagram for CaO with log(ppCO₂) vs temperature. As seen from the phase diagram in FIG. 11, the CO₂ capture or the carbonation step occurs at a lower temperature than the carbonate decomposition step. For a pure stream of CO_(2,) the CaCO₃ need to be decomposed at a temperature greater than 900° C.

From FIG. 10 and FIG. 11, it is evident that the decomposition temperature of CaCO₃+CaFe₂O₄ to Ca₂Fe₂O₅ is 720° C., which is much lower than the 900° C. for CaCO₃ to CaO. Thus, Ca₂Fe₂O₅ shows synergy between Ca and Fe which makes this mixed metal oxide a suitable candidate for exemplary chemical looping systems disclosed herein. Further, the Fe in Ca₂Fe₂O₅ is in +3 oxidation state, which is can be easily reduced to metallic Fe with a hydrocarbon stream. With the reactor schemes disclosed and contemplated herein, this will assist in the conversion of this feed into syngas and/or hydrogen.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Example methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the present disclosure. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional acts or structures. The singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. The present disclosure also contemplates other embodiments “comprising,” “consisting of” and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not.

The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (for example, it includes at least the degree of error associated with the measurement of the particular quantity). The modifier “about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.” The term “about” may refer to plus or minus 10% of the indicated number. For example, “about 10%” may indicate a range of 9% to 11%, and “about 1” may mean from 0.9-1.1. Other meanings of “about” may be apparent from the context, such as rounding off, so, for example “about 1” may also mean from 0.5 to 1.4.

Definitions of specific functional groups and chemical terms are described in more detail below. For purposes of this disclosure, the chemical elements are identified in accordance with the Periodic Table of the Elements, CAS version, Handbook of Chemistry and Physics, 75^(th) Ed., inside cover, and specific functional groups are generally defined as described therein.

For the recitation of numeric ranges herein, each intervening number there between with the same degree of precision is explicitly contemplated. For example, for the range of 6-9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated. For example, when a pressure range is described as being between ambient pressure and another pressure, a pressure that is ambient pressure is expressly contemplated. 

1. A method of operating a reactor system, the method comprising: providing oxygen carrier particles to a first reactor, the oxygen carrier particles comprising a support material and metal oxide; providing flue gas comprising carbon dioxide (CO₂) to the first reactor; operating the first reactor at a temperature of 300° C. to 700° C.; collecting a first reactor gas output comprising less than 1 ppb CO₂; providing the oxygen carrier particles to a second reactor; providing a hydrocarbon stream to the second reactor; operating the second reactor at a temperature of 500° C. to 1100° C.; collecting a second reactor gas output comprising hydrogen gas (H₂) and carbon monoxide (CO); providing the oxygen carrier particles to a third reactor; providing an oxidizing stream to the third reactor; and collecting a third reactor gas output comprising carbon monoxide (CO).
 2. The method of operating the reactor system according to claim 1, wherein the oxidizing stream comprises steam (H₂O) and carbon dioxide (CO₂); and wherein the third reactor gas output further comprises hydrogen gas (H₂).
 3. The method of operating the reactor system according to claim 2, wherein the oxidizing stream further comprises air.
 4. The method of operating the reactor system according to claim 1, wherein the oxidizing stream comprises an oxide of nitrogen (NO_(x)) and carbon dioxide (CO₂); and wherein the third reactor gas output further comprises nitrogen (N₂).
 5. The method of operating the reactor system according to claim 1, wherein the metal oxide is an oxide of calcium (Ca), iron (Fe), nickel (Ni), copper (Cu), manganese (Mn), cobalt (Co), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba).
 6. The method of operating the reactor system according to claim 1, wherein a metal oxide-metal carbonate solid-phase mixture is formed when the oxygen carrier particles contact the flue gas.
 7. The method of operating the reactor system according to claim 6, wherein the metal oxide-metal carbonate solid-phase mixture includes one or more carbonates of calcium (Ca), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba).
 8. The method of operating the reactor system according to claim 1, wherein support material of the oxygen carrier particles comprise silica (SiO₂), magnesia (MgO), alumina(Al₂O₃), ceria (CeO₂), Titania (TiO₂), zirconia (ZrO₂), or combinations thereof.
 9. The method of operating the reactor system according to claim 8, wherein the oxygen carrier particles comprise 20 weight percent (wt %) to 80 wt % support material.
 10. The method of operating the reactor system according to claim 1, wherein the first reactor is operated at a temperature of 400° C. to 660° C.
 11. The method of operating the reactor system according to claim 10, wherein the second reactor is operated at a temperature of 800° C. to 1100° C.
 12. The method of operating the reactor system according to claim 1, further comprising: providing the oxygen carrier particles to a fourth reactor; providing an air stream to the fourth reactor; collecting a fourth reactor gas output comprising depleted air; and providing the oxygen carrier particles to the first reactor.
 13. The method of operating the reactor system according to claim 1, further comprising operating a second reactor system, comprising: providing second oxygen carrier particles to a fifth reactor; providing a second hydrocarbon stream to the fifth reactor; collecting a fifth reactor gas output comprising either hydrogen gas (H₂) and carbon monoxide (CO), or hydrogen gas (H₂), carbon monoxide (CO), carbon dioxide (CO₂) and steam (H₂O); providing the second oxygen carrier particles to a sixth reactor; providing air to the sixth reactor; collecting a sixth reactor gas output comprising depleted air; and providing heat generated in the sixth reactor to the second reactor.
 14. The method according to claim 1, further comprising providing the oxygen carrier particles from the third reactor to a riser; and providing the oxygen carrier particles from the riser to the first reactor.
 15. The method according to claim 1, wherein the hydrocarbon stream includes coal, biomass, natural gas, shale gas, biogas, petroleum coke, or combinations thereof.
 16. A reactor system, comprising: a first reactor comprising: oxygen carrier particles, the oxygen carrier particles comprising a support material and metal oxide; a flue gas inlet in fluid communication with a flue gas source, the flue gas source providing flue gas comprising carbon dioxide (CO₂) to the first reactor; and a first reactor gas outlet configured to provide outlet gas comprising less than 1 ppb CO₂; a second reactor in fluid communication with the first reactor, the second reactor comprising: a hydrocarbon stream input in fluid communication with a hydrocarbon source, the hydrocarbon source configured to provide coal, biomass, natural gas, shale gas, biogas, or petroleum coke to the second reactor; and a second reactor gas outlet configured to provide a second reactor gas output comprising hydrogen gas (H2) and carbon monoxide (CO); and a third reactor in fluid communication with the second reactor, the third reactor comprising: an oxidizing stream inlet in fluid communication with an oxidizing gas source comprising one or more of: steam (H₂O), carbon dioxide (CO₂); and a third reactor outlet gas outlet configured to provide a third reactor gas output comprising carbon monoxide (CO).
 17. The reactor system according to claim 16, wherein the first reactor is arranged as a co-current moving bed, a counter-current moving bed, a fixed bed, or a fluidized bed; wherein the second reactor is arranged as a co-current moving bed, a counter-current moving bed, a fixed bed, or a fluidized bed; wherein the metal oxide is an oxide of calcium (Ca), iron (Fe), nickel (Ni), copper (Cu), manganese (Mn), cobalt (Co), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba); and wherein steam (H₂O) and carbon dioxide (CO₂) are co-injected with the hydrocarbon source.
 18. The reactor system according to claim 16, wherein a metal oxide-metal carbonate solid-phase mixture is formed when the oxygen carrier particles contact the flue gas; wherein the metal oxide-metal carbonate solid-phase mixture includes one or more carbonates of calcium (Ca), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba); and wherein the oxygen carrier particles further comprise support material comprising silica (SiO₂), magnesia (MgO), alumina(Al₂O₃), ceria (CeO₂), Titania (TiO₂), zirconia (ZrO₂), or combinations thereof.
 19. A method of operating a reactor system, the method comprising: providing oxygen carrier particles to a first reactor, the oxygen carrier particles comprising a support material and metal oxide; providing flue gas comprising carbon dioxide (CO₂) to the first reactor; operating the first reactor at a temperature of 300° C. to 700° C.; collecting a first reactor gas output comprising less than 1 ppb CO₂; providing the oxygen carrier particles to a second reactor; providing a hydrocarbon stream to the second reactor; providing an oxidizing stream to the second reactor such that the oxidizing stream is counter-current to the oxygen carrier particles; operating the second reactor at a temperature of 720° C. to 1100° C.; and collecting a second reactor gas output comprising hydrogen gas (H₂) and carbon monoxide (CO).
 20. The method according to claim 19, wherein the hydrocarbon stream is provided to the second reactor such that the hydrocarbon stream is co-current with the oxygen carrier particles; and wherein the oxidizing stream is provided to the second reactor such that the oxidizing stream is counter-current to the oxygen carrier particles; wherein the hydrocarbon stream includes coal, biomass, natural gas, shale gas, biogas, petroleum coke, or combinations thereof; wherein the oxidizing stream comprises steam (H₂O) and carbon dioxide (CO₂); wherein the metal oxide is an oxide of calcium (Ca), iron (Fe), nickel (Ni), copper (Cu), manganese (Mn), cobalt (Co), magnesium (Mg), sodium (Na), potassium (K), lithium (Li), strontium (Sr), or barium (Ba); and wherein the oxygen carrier particles further comprise support material comprising silica (SiO₂), magnesia (MgO), alumina(Al₂O₃), ceria (CeO₂), Titania (TiO₂), zirconia (ZrO₂), or combinations thereof. 